TotGuard 27.5 inch 500w ebike - E09 on display

[BigPapa98]

hi,
I got this ebike from a friend, it's a TotGuard 27.5 inch 500w ebike. It came with no battery or charger.
I found a great deal on a 48v 13ah battery pack, so I bought it. The battery isn't specifically for this bike, so I had to remove the old battery mount, and replace it with the new one. The controller is packed (literally) into the lower section of the battery mount . The bottom part of the controller housing is metal, all wires and c. board are pressed down into it and the housing is then filled some type of silicone glue to hold everything in place. There is a section along the inner right of the housing for the wire connections to be screwed down (no silicone there). the wire comes out of the new housing off-center, so to adapt, I had to remove silicone so I could loosen up some wires. Usually the controller is 1 enclosed unit. In this case, its a single unit, but the battery mount becomes its top cover.

After I get everything put together, power the bike on, and immediately get a E09 code displayed. Lights turn on, horn blows, brake icon shows on display if I squeeze the brake lever. Motor not engaging. Any ideas?

 

[Annieolnie]

Well, you may not have done anything wrong. E09 error on that bike can be a phase wire in the motor or a chafed motor cord, or simply not plugged in properly. Do you have a motor plug somewhere back on the chainstay or do all your wires run directly up to the controller? You can start by checking all the motor connection plugs and also look for any breaks in the wiring.

 

[BigPapa98]

@Annieolnie Thanks for your reply.
All of the wires do connect to the controller. I did a little troubleshooting on my own and worked it out. I decided to remove the battery from the mount and connect it to the terminals on the battery mount using 2 wires. Doing this allowed me to power on the bike and start the motor with no errors. Putting the battery back into the mount and powering up the bike resulted in the E09 error again. I was confident that the connection between the battery and the mount was good, so I figured that the content inside the controller box were getting pressed down harder than they were prior to swapping the housing, and now something was getting shorted out from touching the bottom of the housing (probably part of the circuit board).
The Fix: removed controller contents from housing, placed a few small drops of Krazy glue on inside of housing, used electrical tape to cover the inside surfaces of the housing, places controller contents back in the housing, buttoned everything back up, and all is good now. Installed the battery and she gets up to 22mph.

Thanks again because your response guided me in the right direction to start looking (i,e. something not plugged in, wiring problem]).

 

[Annieolnie]

Well, Yay! You've got a knack for this. Controllers in bases often cause trouble and it can take forever to figure them out because the trouble will come and go, but you nailed it in one! The battery sliding in and out can upset them and they don't like the heat retention either, but your design sounds like a nice improvement. Congratulations.!